# US 10,319,990 B2 · Coated lead acid battery electrode plates; method for making coated electrode plates and lead acid batteries containing coated electrode plates > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,319,990 B2 - Document ID: US10319990B2 - Status: Granted - Kind: B2 - Application number: 15/644,688 - Filed: 2017-07-07 - Published: 2018-02-08 - Granted: 2019-06-11 - Earliest claimed: 2016-08-05 - Assignees: Trojan Battery Ireland Ltd. - Applicants: Trojan Battery Ireland Ltd - Inventors: Cormac O'Keeffe; Marvin Ho - Web page: https://patentgrep.com/patent/US10319990B2 ## CPC - H01M 4/22: Forming of electrodes - H01M 4/366: {as layered products} - H01M 4/56: of lead - H01M 4/662: {Alloys (collectors of lead alloys H01M4/685)} - H01M 4/685: {Lead alloys} - H01M 4/73: for lead-acid accumulators, e.g. frame plates - H01M 10/121: {Valve regulated lead acid batteries [VRLA]} - H01M 50/403: Manufacturing processes of separators, membranes or diaphragms - H01M 50/411: Organic material - H01M 50/44: Fibrous material - H01M 50/46: Separators, membranes or diaphragms characterised by their combination with electrodes - H01M 10/06: Lead-acid accumulators (semi-lead accumulators H01M10/20) - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract Disclosed are electrode plates for a lead acid battery. The electrode plates are formed of an electrode plate having a face, the electrode plate comprising a lead or lead alloy grid coated with an active material and the electrode plates having a porous, non-woven mat comprised of polymer fibers coating on the face of the electrode plate, as well as a method for making the coated electrode plates and lead acid batteries containing the coated electrode plates. ## Claims ### Claim 1 An electrode plate for a lead acid battery having a coating comprising: an electrode plate for a lead acid battery comprising a lead or lead alloy grid coated with an active material and a porous, non-woven mat comprised of polymer fibers arranged with the electrode plate. ### Claim 2 (depends on 1) The electrode plate of claim 1 wherein the lead alloy is a lead-antimony, a lead-calcium or a lead-tin grid. ### Claim 3 (depends on 2) The electrode plate of claim 2 wherein the alloy is a lead-antimony alloy. ### Claim 4 (depends on 2) The electrode plate of claim 2 wherein the active material is a lead oxide active material. ### Claim 5 (depends on 1) The electrode plate of claim 1 wherein the polymer fibers have a fiber diameter of from about 5 nm and about 30 μm. ### Claim 6 (depends on 1) The electrode plate of claim 1 wherein the polymer fibers have a fiber diameter of from 500 nm to about 1 μm. ### Claim 7 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g. ### Claim 8 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g. ### Claim 9 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a porosity of from 30% to about 90%. ### Claim 10 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a porosity of from about 50% to about 70%. ### Claim 11 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm. ### Claim 12 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm. ### Claim 13 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm. ### Claim 14 (depends on 1) The electrode plate of claim 1 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof. ### Claim 15 (depends on 14) The electrode plate of claim 14 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers. ### Claim 16 (depends on 1) The electrode plate of claim 1 wherein the polymer fiber coating further comprises an active agent. ### Claim 17 (depends on 16) The electrode plate of claim 16 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof. ### Claim 18 (depends on 1) The electrode plate of claim 1 wherein the electrode plate is a positive electrode plate for a lead acid battery. ### Claim 19 (depends on 1) The electrode plate of claim 1 wherein the electrode plate is a negative electrode plate for a lead acid battery. ### Claim 20 (depends on 1) The electrode plate of claim 1 wherein the electrode plate comprises a face, and the porous, non-woven mat is coated on the face of the electrode plate. ### Claim 21 A method for coating an electrode plate for a lead acid battery comprising the step of: electrospinning a polymer onto the surface of an electrode plate collector, the electrode plate collector comprising a lead or lead alloy grid coated with an active material, to form a porous, non-woven mat coating comprised of polymer fibers on the surface of the electrode plate collector. ### Claim 22 (depends on 21) The method of claim 21 wherein the lead alloy grid is a lead-antimony, a lead-calcium or a lead-tin alloy grid. ### Claim 23 (depends on 22) The electrode plate of claim 22 wherein the alloy is a lead-antimony alloy. ### Claim 24 (depends on 23) The electrode plate of claim 23 wherein the active material is a lead oxide active material. ### Claim 25 (depends on 21) The method of claim 21 wherein the polymer fibers comprising the porous, non-woven mat coating have a fiber diameter of from 5 nm and about 30 μm. ### Claim 26 (depends on 21) The method of claim 21 wherein the polymer fibers comprising the porous, non-woven mat coating have a fiber diameter of from 500 nm to about 1 μm. ### Claim 27 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g. ### Claim 28 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g. ### Claim 29 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a porosity of from 30% to about 90%. ### Claim 30 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a porosity of from about 50% to about 70%. ### Claim 31 (depends on 21) The method of claim 21 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof. ### Claim 32 (depends on 31) The method of claim 31 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers. ### Claim 33 (depends on 21) The method of claim 21 further comprising the step of formulating the polymer to be electrospun spun as a solution comprising the polymer and a solvent for the polymer. ### Claim 34 (depends on 33) The method of claim 33 wherein the polymer solution further comprises an active agent. ### Claim 35 (depends on 34) The method of claim 34 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof. ### Claim 36 (depends on 33) The method of claim 33 wherein the solvent is formic acid, dimethyl formamide, n-methylpyrrolidone, acetone, ethyl acetate, propyl acetate, water, dichloromethane, tetrahydrofuran, isopropyl alcohol, dicloromethane, ethanol, methanol, chloroform, acid acid, trifluoroacetic acid, trifluoroethanol, hexafluoro propanol, dimethylacetamide, carbon disulfide, cyclohexane, toluene, N-methylmorpholine, xylenes and dimethylsulfoxide or combinations thereof. ### Claim 37 (depends on 36) The method of claim 36 wherein the solvent is formic acid or dimethyl formamide. ### Claim 38 (depends on 31) The method of claim 31 further comprising the step of formulating the polymer to be electrospun spun as a polymer melt. ### Claim 39 (depends on 38) The method of claim 38 wherein the polymer melt further comprises an active agent. ### Claim 40 (depends on 39) The method of claim 39 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof. ### Claim 41 (depends on 31) The method of claim 31 wherein the electrode plate collector is a positive electrode plate for a lead acid battery. ### Claim 42 (depends on 31) The method of claim 31 wherein the electrode plate collector is a negative electrode plate for a lead acid battery. ### Claim 43 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm. ### Claim 44 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm. ### Claim 45 (depends on 21) The method of claim 21 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm. ### Claim 46 A lead acid battery comprising: a housing containing a negative electrode plate; a positive electrode plate, where the electrode plates are comprised of a lead or lead alloy grid coated with an active material; a separator disposed between the first and second electrode plates; an electrolyte immersing the negative electrode plate, the positive electrode plate the separator; a porous, non-woven mat comprised of polymer fiber arranged with one of the electrode plates. ### Claim 47 (depends on 46) The lead acid battery of claim 46 wherein the lead alloy grid is a lead-antimony, a lead-calcium or a lead-tin alloy grid. ### Claim 48 (depends on 47) The lead acid battery of claim 47 wherein the alloy is an antimony. ### Claim 49 (depends on 46) The lead acid battery of claim 46 wherein the active material is a lead oxide active material. ### Claim 50 (depends on 46) The lead acid battery of claim 46 wherein the polymer fibers have a fiber diameter of from 5 nm and about 30 μm. ### Claim 51 (depends on 46) The electrode of claim 46 wherein the polymer fibers have a fiber diameter of from 500 nm to about 1 μm. ### Claim 52 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a surface area of from 5 m2/g to about 500 m2/g. ### Claim 53 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a surface area of from 50 m2/g to about 200 m2/g. ### Claim 54 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a porosity of from 30% to about 90%. ### Claim 55 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a porosity of from about 50% to about 70%. ### Claim 56 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 2 μm to about 2 mm. ### Claim 57 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 5 μm to about 500 μm. ### Claim 58 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating has a thickness of from about 20 μm to about 250 μm. ### Claim 59 (depends on 46) The lead acid battery of claim 46 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene, Nylon 6, carboxymethyl cellulose, polyacrylic acid, polyvinyl alcohol, polylacetic acid, polyethylene-co-vinyl acetate, polymethyacrylate/tetrahydroperfluorooctylacrylate, polyethylene oxide, polymethacrylate, polyamide, polycaprolactone, polyethyl imide, polycaprolactam, polyethylene terephthalate, polyphenyl ether, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, poly(vinylidenefluoride-co-hexafluoropropylene, polyvinyl-pyridine, polylactic acid, polypropylene, polybutylene, polybutylene terephthalate, polyamide, polyimide, polycarbonate, polytetrafluoroethylene, polyester, acrylonitrile butadiene styrene, poly(methyl methacrylate), polyoxymethylene, polysulfone, styrene-acrylonitrile, polyacrylonitrile, styrene-butadiene rubber, ethylene vinyl acetate, styrene maleic anhydride, polyisoprene, natural rubber, cellulose, cellulose acetate, polyaniline, polyacrylonitrile, poly (ε-caprolactone), chitosan, Gelatin, Polyurethanes, poly (3-hydroxybutrate-co-3-hydroxyvalerate), polystyrene-block-polyisoprene-block-polystyrene fibers or combinations thereof. ### Claim 60 (depends on 59) The lead acid battery of claim 59 wherein the polymer fibers are cellulose acetate, polystyrene, polyethylene or Nylon 6 fibers. ### Claim 61 (depends on 46) The lead acid battery of claim 46 wherein the polymer fiber coating further comprises an active agent. ### Claim 62 (depends on 61) The lead acid battery of claim 61 wherein the active agent is natural rubber, RSS 1 or V 60 rubber, a macromolecule, a chelating agent, silica, carbon black or combinations thereof. ### Claim 63 (depends on 46) The lead acid battery of claim 46 wherein the lead acid battery is a flooded lead acid battery or a valve regulated lead acid battery. ### Claim 64 (depends on 63) The lead acid battery of claim 63 wherein the lead acid battery is a flooded lead acid battery. ### Claim 65 (depends on 63) The lead acid battery of claim 63 wherein the lead acid battery is a valve regulated lead acid battery. ### Claim 66 (depends on 65) The lead acid battery of claim 65 wherein the valve regulated lead acid battery is an AGS lead acid battery or a gel lead acid battery. ### Claim 67 (depends on 49) The lead acid battery of claim 49 wherein the negative electrode plate comprises a first face and the positive electrode plate comprises a second face opposing the first face, and wherein the porous, non-woven mat is coated on said one of the electrode plates.